Lincoln Electric POWER WAVE S500 Operator'S Manual Download Page 12

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TEMPERATURE RANGES

HEIGHT

22.45 in ( 570 mm)

MODEL

K2904-1

WIDTH

14.00in ( 356 mm)

DEPTH

24.80in ( 630mm)

WEIGHT

150 lbs (68 kg)

OPERATING TEMPERATURE RANGE

Environmentally Hardened: -4°F to 104°F (-20C to 40C)

STORAGE TEMPERATURE RANGE

Environmentally Hardened: -40°F to 185°F (-40C to 85C)

PROCESS

GMAW

GMAW-Pulse

FCAW

GTAW-DC

SMAW

OUTPUT RANGE (AMPERES)

40-550A

5-550A

15-550A

OCV (U

)

Mean Peak

60V

100V

24V
60V

WELDING PROCESS

A-2

INSTALLATION

POWER WAVE

S500

IP23 155º(F) Insulation Class

Weight does not include input cord.

Thermal tests have been performed at ambient tem-
perature. The duty cycle (duty factor) at 40°C has
been determined by simulation.

PHYSICAL DIMENSIONS

Summary of Contents for POWER WAVE S500

Page 1: ...having Code Numbers 12772 12773 12774 12775 Need Help Call 1 888 935 3877 to talk to a Service Representative Hours of Operation 8 00 AM to 6 00 PM ET Mon thru Fri After hours Use Ask the Experts at l...

Page 2: ...A LARGE ROOM OR OUTDOORS natural ventilation may be adequate if you keep your head out of the fumes See below USE NATURAL DRAFTS or fans to keep the fumes away from your face If you develop unusual s...

Page 3: ...rs and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment 1 e In some case...

Page 4: ...to ANSI Z87 I standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 4 c Protect other nearby personnel with su...

Page 5: ...nt passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c 6 I Read and follow N...

Page 6: ...i s et non inflamma bles 4 Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pant...

Page 7: ...t used for calibration or measurement g the immunity of other equipment in the environment The user shall ensure that other equipment being used in the environment is compatible This may require addit...

Page 8: ...BOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL B 1 PRODUCT DESCRIPTION B 2 RECOMMENDED PROCESSES AND EQUIPMENT B 2 PROCESS LIMITATIONS B 2 EQUIPMENT LIMITATIONS B 2 DESIGN FEATURES B 2 S500 CASE F...

Page 9: ...olts INPUT VOLTAGE PHASE FREQUENCY 200 208 3 50 60 230 3 50 60 380 415 3 50 60 460 3 50 60 575 3 50 60 Input Amperes 80 73 41 37 29 60 54 30 27 21 Idle Power 500 Watts Max fan on Power Factor Rated Ou...

Page 10: ...00 Amps 39 Volts INPUT VOLTAGE PHASE FREQUENCY 380 415 3 50 60 460 3 50 60 575 3 50 60 Input Amperes 41 37 29 30 27 21 Idle Power 500 Watts Max fan on Power Factor Rated Output 95 Input Voltage 10 400...

Page 11: ...an on Power Factor Rated Output 95 Input Voltage 10 230 400 460 575 50 60 Hz includes 380V to 415V For voltages higher than 460V or applications outside the European union replace input cord with prop...

Page 12: ...ronmentally Hardened 40 F to 185 F 40C to 85C PROCESS GMAW GMAW Pulse FCAW GTAW DC SMAW OUTPUT RANGE AMPERES 40 550A 5 550A 15 550A OCV Uo Mean Peak 60V 100V 24V 60V WELDING PROCESS A 2 INSTALLATION P...

Page 13: ...all sides This equipment is for industrial use only and it is not intended for use in residential locations where the electrical power is provided by the public low voltage supply system There can be...

Page 14: ...rmal magnetic circuit breakers Choose input and grounding wire size according to local or national electrical codes Using input wire sizes fuses or circuit breakers smaller than recommended may result...

Page 15: ...ds on the new power cord in the same location and with the same number of turns CONNECT EACH PHASE OF A THREE PHASE CONDUCTOR HERE INPUT POWER ACCESS DOOR INPUT CORD STRAIN RELIEF CE FILTER GROUND CON...

Page 16: ...R R G GA AS S H HO OS SE E F FO OO OT T A AM MP PT TR RO OL L K K87 870 0 W WO OR RK K P PI IE EC CE E W WO OR RK K C CL LA AM MP P T TI IG G T TO ORC RCH H K K2 22 26 66 6 1 1 K KI IT T I INC NCL LUD...

Page 17: ...rol panel can be installed into the power source Figure A 3 The connection diagram shown is based on the S Series user interface K3001 2 In this diagram the remote control box is optional REMOTE CONTR...

Page 18: ...ails R RE EG GU UL LA AT TO OR R F FL LO OW WM ME ET TE ER R G GAS AS H HO OS SE E W WO OR RK K P PI IE EC CE E W WO OR RK K C CL LA AM MP P T TO O P PO OS SI IT TI IVE VE S ST TU UD D T TO O N NE EG...

Page 19: ...e Always use the largest welding cables electrode and work that are practical and be sure all connections are clean and tight Note Excessive heat in the weld circuit indicates undersized cables and or...

Page 20: ...te sense leads are connected With this feature there are no requirements for setting up the machine to use remote sense leads This feature can be disabled through the Weld Manager Utility available at...

Page 21: ...The remote WORK sense lead 21 can be accessed through the four pin voltage sense connector located on the control panel by using the K940 Sense Lead Kit It must be attached to the work as close to th...

Page 22: ...ads ARE Used Position the sense leads out of the path of the weld current Especially any current paths common to adjacent arcs Current from adjacent arcs can induce voltage into each others current pa...

Page 23: ...AVE S500 For circumferential applications connect all work leads on one side of the weld joint and all of the work voltage sense leads on the opposite side such that they are out of the current path S...

Page 24: ...the power source to the wire feeder The control cable consists of two power leads one twisted pair for digital communication and one lead for voltage sensing The 5 pin ArcLink connection on the Power...

Page 25: ...rotection SEE ADDITIONAL WARNING INFORMATION UNDER ARC WELDING SAFETY PRECAUTIONS AND in the FRONT OF THIS OPERATING MANUAL POWER UP SEQUENCE When the POWER WAVE S500 is powered up it can take as long...

Page 26: ...th an output range of 5 to 550 amperes it supports a number of standard processes including synergic GMAW GMAW P FCAW FCAW SS SMAW GTAW and GTAW P on various materials especially steel aluminum and st...

Page 27: ...7 Work Sense lead CONNECTOR 8 12 Pin CONNECTOR optional FIGURE B 1 CASE BACk CONTROLS See Figure B 2 1 115 VAC CIRCUIT BREAKER 2 115 VAC RECEPTACLES 3 Reserved for future development 4 SYNC TANDEM ST...

Page 28: ...ode Stud 7 Work Sense lead 8 12 PIN REMOTE optional FIGURE B 1 S500 CE S500 CE CASE BACk CONTROLS See Figure B 2 S500 CE 1 Gas Inlet optional 2 Reserved for future development 3 SYNC TANDEM STT CONNEC...

Page 29: ...ng mode offers the simplicity of single knob control The machine will select the correct voltage and amperage based on the Wire Feed Speed WFS set by the operator Basic Welding Controls Weld Mode Sele...

Page 30: ...wire feed speed a corresponding voltage is prepro grammed into the machine through special software at the factory The nominal preprogrammed voltage is the best average voltage for a given wire feed...

Page 31: ...50 to 1 25 At very low or high wire feed speeds the adaptive range may be less due to reaching physical limitations of the welding process UltimArc Control adjusts the focus or shape of the arc UltimA...

Page 32: ...ffers a wide range of fume extraction environmental system solutions ranging from portable systems easily wheeled around a shop to shop wide central systems servicing many dedicated welding stations R...

Page 33: ...critical to its operation Generally speaking the calibration will not need adjustment However neglected or improperly calibrated machines may not yield satisfactory weld performance To ensure optimal...

Page 34: ...USE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it...

Page 35: ...e system configuration is changed during operation Fast Blinking Green Indicates Auto mapping has failed Alternating Green and Red Non recoverable system fault If the Status lights are flashing any co...

Page 36: ...contact the Service Department Review error code from input board status light or status beeper Most likely caused by an over power condition which caused an under voltage on the primary bus If cycli...

Page 37: ...y a fan malfunction or blocked air vent Temporary 337 Precharge Timeout The DC bus voltage was not charged to a certain level at end of precharge If problem persists contact Service Department Persist...

Page 38: ...ut current duty cycle or both 3 Contact your local authorized Lincoln Electric Field Service facility for technical assistance 1 Make sure input supply disconnect has been turned ON Check input fuses...

Page 39: ...ections or faulty thermostats in the thermostat circuit 1 Replace the battery Type BS2032 1 Check for feeding problems 2 Check for bad connections excessive loops in cable etc NOTE The presence of hea...

Page 40: ...g This condition will also result in a status light blinking See the Status Light section for more information 1 Make certain that the input voltage is proper according to the Rating Plate located on...

Page 41: ...formation has been entered 2a Verify no duplicate the IP addresses exist on the network 3 Verify that the network device connected to the Power Wave is either a 10 baseT device or a 10 100 baseT devic...

Page 42: ...5 4 8 1 2 1 6 6 12 1 J10A1 J10B1 J811 J2 J3 J4 J45 J61 J86 J2 J5 J11 J31 J46 J51 J111 J82 J81 J9 J13 J16 J26 J27 J62 J112 J83 J1 J8 J24 J28 J29 J43 J47 J63 J84 J12 J23 J25 J42 J6 J7 J41 J85 J87 INPUT...

Page 43: ...2 HIGH C DIFF_2 LOW D E F 1 J50 2 3 4 357 354 352 349 B R R 250 OHM 25 W 250 OHM 25 W M20305 1 WORK 206E 206C 202 202B 67C 67D 67F J36 2 1 4 6 3 5 8 7 51A 9 10 12 J23B 8 11 3 4 5 6 7 2 13 14 15 16 1 3...

Page 44: ...2 9 8 16 1 4 6 1 3 5 4 8 1 2 1 6 6 12 1 J10A1 J10B1 J811 J2 J3 J4 J45 J61 J86 J2 J5 J11 J31 J46 J51 J111 J82 J81 J9 J13 J16 J26 J27 J62 J112 J83 J1 J8 J24 J28 J29 J43 J47 J63 J84 J12 J23 J25 J42 J6 J7...

Page 45: ...F 4 DIAGRAMS POWER WAVE S500 L16215 A 01 13 94 22 45 27 43 6 00 18 35 24 76 POWER WAVE S500 S500CCC DIMENSIONAL PRINT...

Page 46: ...F 5 DIAGRAMS POWER WAVE S500 2 12 27 43 22 45 13 96 6 00 24 76 18 35 POWER WAVE S500 CE DIMENSIONAL PRINT...

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Page 50: ...parts or electrode with skin or wet clothing l Insulate yourself from work and ground l No toque las partes o los electrodos bajo carga con la piel o ropa moja da l Aislese del trabajo y de la tierra...

Page 51: ...d Entl ftung des Arbeitsplatzes l Mantenha seu rosto da fuma a l Use ventila o e exhaust o para remover fumo da zona respirat ria l Turn power off before servicing l Desconectar el cable de ali mentac...

Page 52: ...tomer s particular purpose with respect to such information or advice As a matter of practical consideration we also cannot assume any respon sibility for updating or correcting any such information o...

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